Separation Technology for the Chemical Process Industry

Home , Chemical process, Reactive distillation

SulzerSulzer ChemtechChemtech

0699 2531-5 Technology Leadership

The chemical process industry has always been the driving force for Sulzer Chemtech’s innovations. In the early 1960’s, the stringent requirements for the purification of heat-sensitive fragrances led to the development of the Sulzer Packing BX, which set a new standard for vacuum distillation and led to the development of many other unique products.

Sulzer Chemtech Achievements: 1964 BX gauze packing for distillation of heat- sensitive fragrances 1977 Mellapak for styrene/ethylbenzene towers 1980 Nutter SVG tray for ethanol separation 1986 Safety concept for hydrogen peroxide Industrial Applications from A to Z purification Acetates 21 1988 Heat pump system for styrene/ethylbenzene towers Acetic Acid 14 1992 Crystallization plant for acrylic acid Air Separation 17 1998 Vapor Permeation Membranes to break Alcohols 3 solvent azeotropes economically Aromatics 4-5 1999 Katapak for the reactive distillation of acetates Caprolactam 10-11 1999 MellapakPlus for styrene towers Diisocyanates 8-9 2000 Shell HiFi tray for xylene splitters Divided Wall Columns 22 Flavours, Fragrances 15 For classical column operations like distillation, ab- Hydrogen Peroxide 18-19 sorption and extraction, and for alternatives such as crystallization, membrane permeation and reactive Oleochemicals 12-13 distillation, we are continuously developing new pro- Pharmaceutical Solvents 20 duct ideas to meet the economical and technical ob- jectives of our customers. For numerous applications Styrene 6-7 Sulzer Chemtech provides superior plant performance, Tall Oil 16 improved product quality, increased capacity, and reduced energy demand. Terephtalic Acid 14 Vitamins 15 Sulzer Chemtech offers a full range of column internals with trays, structured packing, and random packing embedded in column simulation, process design, basic engineering and field services. Color index of the diagrams

Sulzer Chemtech is a worldwide leading supplier for • Structured packing separation technology, thanks to our customers and • Trays the confidence they instill into our products and our capabilities. • Random packing From the very first to the very last of our more than • Catalyst 30.000 columns in operation, we have never stopped listening to our customers about their needs. At Sulzer • Mixers Chemtech, we are eager to learn how we can develop • Membrane a successful application for your needs.

2 Alcohols

Bioethanol: A source of alternative fuels.

Bioethanol, which can be used as Ethanol an automotive fuel by itself or mix- ed with conventional fuels, is made of agricultural products, including Rectifier waste water. The use of this renewable energy Yeast / Sugar / Water source as fuel has the benefits Draw of cleaner combustion and lower emissions of carbon dioxide.

Bioethanol is produced through a biological fermentation process, Fermentation Beer still Side stripper followed by distillation/rectification and dehydration.

Due to the presence of solids this process is known as a fouling Steam service. Sulzer Chemtech has extensive experience in the use of Water trays for fouling services. Solids / Water

SVGTM Trays for Fouling Services

The SVG fixed valve is perfect in fouling services:

• The lateral vapour release from the SVG allows for a cleaning action on the tray deck, which minimizes fouling • The SVG has a flexible operating range due to the different valve lifts available • The fixed valve trays are very stable from a mechanical point of view • The valve is situated such that it operates parallel to flow, therefore no inlet bars or inlet 0602 2512 weirs are required • The position of the valve is such that the liquid will have no vapour obstructions as the liquid flows across the tray

3 Aromatics

Benzene- Toluene- Xylene (BTX) Aromatics Solvent Raffinate Light Ends Extraction Aromatics are produced in large Benzene quantities in catalytic reforming. They can be converted and reco- Toluene vered by extraction, crystallization CCR and distillation in order to maximize yields of desirable products such CH3 as benzene, toluene and xylene.

In a complete aromatic unit, a Xylene p-Xylenes variety of columns with trays are Separation Light present. Sulzer has experience in Ends applications with columns with a Isomerization diameter of 0.7 up to 10 meters. o-Xylene Shell Calming SectionTM and Shell CH3 HiFiTM trays are successfully being CH used in aromatic duties like the 3 BTX recovery section. C9+

Xylene Separation P-xylene can be economically se- parated from m-xylene through crystallization. With Sulzer Chemtech’s static crystallization process, it is possible to produce p-xylene with a purity of 99.9% and m-xylene with SMVP Extraction Packing: a purity of 99.5%. For revamping existing columns for capacity/efficiency increase: • Increase of viscosity index • Increase of thermal/chemical Shell Calming Section Trays stability of the lube oil • Maximizes bubbling area • Highest jet flood and vapor handling capacity • Long flow path length • High efficiency • Available in boltless construction • Minimum installation time • Can use many types of bubblers (sieves, valves, fixed 0602 2513-1 valves, etc.) • Small tray spacing to provide maximum stages 0682 2064 0682 • Several hundred columns in operation

4 Nitrochlorobenzene-Isomers (NCB) p-NCB 95% Similar to other isomer separation m-, p-NCB processes, the separation of NCB- LB o-NCB 95% isomers requires multiple theoretical stages. In addition the heat sensitivity of these substances creates further difficulties in the design of distillation columns, m-,o-, p-NCB thereby necessitating the use of +LB +HB structured packing like the Sulzer

BX and Mellapak. Cristallizer

p-NCB 95%

The low pressure drop of our The combination of distillation with structured packing offers a strong a melt crystallization create further advantage to avoid the temperature advantages for the product purity. 0602 2510 limits of the explosive mixtures. Mellapak 250.Y

Dichlorobenzene-Isomers (DCB) The separation of DCB is maxi- >99% m-DCB mized by the use of extractive distillation. With the optimal entrainer, the relative volatility (α-value) can be increased, resulting in more economical columns. Sulzer Chemtech has extensive m-, o-, DCB experience in the design of trays, m-, o-, p-DCB packing and internals for extractive Entrainer distillation columns such as for dichlorobenzene, dichlorotoluene, and for the separation of aromatics from non aromatics.

Extractive dist. column Stripper

5 Styrene - Leadership in Distillation and Mixing Technology

Styrene Monomer Purification Alkylation Benzene Recovery Ethylbenzene Recovery Dehydrogenation Structured sheet metal packings have been in commercial use since the mid 70’s with ever growing Inhibiter BE Inhibiter areas of application due to high separation performance and low pressure drop. Today more than Ethylene 100 columns for styrene monomer Lights distillation have been equipped by Sulzer Chemtech with structured Ethylene Steam packing (representing 70% of the world capacity). Ethylene Drivers for structured packing to- wards mass transfer trays Benzene Flux Oil • Prevention of polymer formation because of reduced pressure PEB drop leading to low bottom Ethylene temperatures BE • Reduction of inhibitor consumption because of reduced mean residence time and smaller residence time distribution SM • Increase in capacity, yield and storage purity TO/BE BE SM SM • Energy savings by increasing the number of theoretical stages and Sulzer heat pump technology Inhibiter

Inhibiter

TO SM finishing system EB/SM Inhibiter EB/SM splitter with vapor TAR recompression

Styrene Purification

MellapakPlus - A New • Lower fouling risk by smooth Generation and steady change of gas flow • MellapakPlus represents the direction and reduced local newest, high-capacity struc- liquid holdup accumulation at tured packing generation. In ad- the intersection between two dition to the above mentioned layers advantages MellapakPlus offers The performance of MellapakPlus the following benefits for styrene is confirmed by Fractionation Re- search, Inc. (FRI) and more than 15 distillation: 0691 2522-3 0691 2522-4 • Additional 30 - 50% capacity columns for styrene purification are Mellapak MellapakPlus • Remarkable lower pressure in operation with MellapakPlus drop compared to conventional around the world. structured packing

6 Dehydrogenation Offgas treatment Sulzer / Shell Tray Technology

Offgas

Steam 0602 2512

Steam Steam

Flux Oil Condensate

EB SM

0602 2513-2

Offgas Separation Trays for your Monomers Ethylbenzene Recovery SM storage Conventional trays • Sieve tray • Valve tray Oligomers • Sulzer SVG / MVG tray • Bubble cap tray • Dualflow tray • Baffle tray

High performance trays for revamps Polymers • Sulzer Vortex tray • Sulzer MVGT tray • Shell Calming Section / Additives HiFi tray Polymerisation • Shell Consep tray

Sulzer SMR Static Mixer Reactors They are installed in more than 15 styrene polymerisation plants, 0691 2724-3 where they provide: • High heat transfer in small Sulzer Static Mixers SMV volume are installed in the ethylbenzene • Narrow residence time dehydrogenation reactor section distribution of more than 50 plants. They • Low pressure drop reduce the temperature difference 0699 2706-3 down to +/- 2 °C at reactor inlet with minimum pressure drop.

7 Diiscoyanates - Purification Technology for all Demands

Diisocyanates MDI & TDI MDI Process Toluene diisocyanate (TDI) and methylene diphenyl diisocyanate Acid Catalytic Condensation MDA Purification (MDI) are the most commonly used source for polyurethane production Aniline (foams for insulation, furnitures, MDA automotive industry).

H2N NH2 CH2 Toluene Diisocyanate All common processes to produce TDI involve purification units for H2C =O preproducts like dinitro toluene (DNT) and toluene diamine (TDA). Removing impurities of hydrochloric acid, phosgen and solvent is similar to the process involved in the pro– duction of MDI. Since TDI has to be purified to market specifications, Sulzer Chemtech offers a wide range of technologies to meet the customer‘s specific requirements. More than 25 distillation services and two crystallization units with Sulzer Chemtech technology are in operation. Distillation

Methylene Diphenyl Diisocyanate Beside MDA distillation and the different kinds of absorbers and strippers for phosgenation, we are focused on the purification MDI at its final stage. MDI has the tendency Your Advantages with Sulzer Chemtech: during the purification process to • MellapakPlus the packing with lowest pressure drop form dimers resp. polymers at • Comprehensive experience with liquid distributors high temperatures and residence • Safe column design based on pilot tests times. Therefore,low pressure drop • Performance guarantee and few liquid holdup are decisive • Many industrial references (> 35) criteria for the final product quality. • Knowlegeable on heat exchanger design 0600 2503-1 0600 2503-3

0691 2522-3 0691 2522-4 Mellapak MellapakPlus Splash plate distributor

8 Neutralization Phosgenation MDI Purification

NaOH COCI2

MDI

OCN CH2 NCO

Methylenediphenyl diisocyanate

Stripping and Drying Absorption Distillation Crystallization

CI2 Treatment Impurities removal MDI Purification at HCI Electrolysis • Phosgene traces • Solvent (MBC or o-DCB recovery) • HCI • Crude distillation • Solvent traces • 2,2'- / 2,4' - / 4,4'- Isomer separation

Absorption & Stripping Distillation of MDI Crystallization of MDI Sulzer has many years of experi- Paying attention to the following Crystallization is the most gentle ence in stripping and drying key features will lead to a success- way to purify MDI for the poly- columns for the treatment of ful column design: urethane market, a process with chlorine and hydrochloric acid, as • Pressure drop high yield at low energy cost. The well as the removal of phosgene • Bottom temperature maximum temperature required is and solvent traces by absorption. • Liquid holdup (residence time) approxately 40 °C. Depending on More than 100 hydrochloric acid • Plugging risk of distributor feed and product specification, absorbers are in operation with • Dimer, polymer formation crystallization is a very competi- 0600 2503-1 Sulzer Mellapak. • Product color tive technology compared to distillation. However, Sulzer Chemtech provides both technologies in a combination leading to a maximum of plant flexibility in terms of capacity, product yield and quality. 0682 2021 0682 2017

Mellapak in plastic BX gauze packing

9 Caprolactam - Gentle Purification with Sulzer Chemtech Technology

Sulzer Services for Caprolactam Oxydation Saponification Distillation Plants • Column simulation and design • Feasibility studies for Cyclo- Lights hexanone/OL H2O debottlenecking • Extended performance guarantee NaOH • Troubleshooting • Column scanning • Pilot testing • Field supervision • Installation Cyclohexane

Purification of Cyclohexanone The main route (85% of world Caustic soda capacity) for conventional produc- Air tion of caprolactam is based on phenol or cyclohexane producing Lactam oil cyclohexanone, which is converted via cyclohexanone oxime to caprolactam. For the purification of cyclohexanone today, most distillation columns are equipped with structured packing to Cyclo- NH hexanone handle temperatures below 90 °C. 3 Phase MellapakPlus is Sulzer’s latest, ad- Oleum separator vanced technology for this sepa- Hydroxylamine ration to realize purities >99.95% sulfate wt. cyclohexanone.

Ammoniumsulfate to cristallization Raffinate

Ammoximation, Rearrangement, Neutralization Extraction

Structured Packing Drivers • Higher capacity (small columns) • Low pressure drop for operating with advantageous equilibrium • Fewer holdup • Higher separation efficiency leading to low energy consumption

• Large turndown flexibility 2510 0602

10 Caprolactam - Gentle Purification with Sulzer Chemtech Technology

Distillation Dehydrogenation Purication of Caprolactam Caprolactam is very heat sensitive. To prevent decomposition of the product, distillation columns for the Cyclohexanone Cyclohexanol separation from heavy and light boiling impurities must be operated at temperatures below 140 °C. The range of admissible impurities is some ppm. Product color is also an important quality feature.

This results in low vacuum (2-20 mbar) operating column conditions, where Anone/OL • Low pressure drop • Low liquid holdup Residue • Low mean residence time • Narrow residence time distribution are decisive for the success of our customers H2O Lights Caprolactam

H O 2 Fractional Crystallization equals Premium Quality Crystallization is used as final purification step (topping of distillation). It is an effective and competitive technology to produce a premium quality product that is environmentally safe and benefits from high flexibility at a low energy and maintenance cost. Sulzer offers Solvent Heavies proprietary falling film technology for Solvent preparation caprolactam purification.

Extraction Distillation

Distillation: Our Success • Sulzer offers the lowest pressure drop per theoretical stage in the market with MellapakPlus • Many years of experience in equipment design (columns, heat exchangers, control systems) • Columns with BX, Mellapak and MellapakPlus at all main caprolactam producers 0682 2017 • More than 20 distillation units with Sulzer column internals in operation

11 Oleochemicals - Step into a growing Market with Sulzer Chemtech

Sulzer Chemtech benefits from decades of experience distilling Hydro- oleochemicals (fatty acids, fatty Splitting, hydrolysis Fatty genation alcohols, fatty acid esters). Pilot acid distillation experiments have been performed in Winterthur (Switzer- Fat Edible and Glycerol Fatty land) and in-house vapor-liquid- fat and oil Oil alcohol equilibrium (VLE) parameters are available. It is estimated that today more than 500 industrial co- Removal of Fatty acid free fatty acid Transesterfication methyl ester Hydro- lumns, utilizing Sulzer Chemtech genation structured packing and internals, are in operation. Overview of Fat and Oil Processes

Fatty Acid Distillation Fatty acids are saturated and un- saturated aliphatic carboxylic acids with carbon chain length in the Fatty acid Fatty acid Fatty acid range of C up to C . CA CB CC 6 24 Water and uncondensed Example: palmitic acid, components CH3 - (CH2)14 - COOH

Knowledge of the chemical and physical properties of fatty acids is one of the basic prerequisites Drying for industrial manufacturing and Column technical applications. Thermody- namic data are necessary for the calculation of heat transfer and thermal separation. Sulzer Chemtech has the know- Crude Fatty acid Fatty acid Fatty acid Residue fatty acid C C C how, the extensive experience ABC BC C and the structured packing with Multipurpose Fatty Acid Distillation Plant internals to ensure the most gentle In the oleochemical production of requirements, glycerol can be pu- distillation of fatty acids. fatty alcohols, molecules never rified up to: have a uniform carbon chain • Technical grade by atmospheric Further specialties in this field are: length. For purification and quality drying • Multipurpose fatty acid improvement, the fatty alcohol • Pharmaceutical grade by distillation plants mixture has to be distillated. For vacuum distillation • Separation of C ’ / C ’’ / C ’’’ 18 18 18 this separation and purification, • Liquid / gas side product draw- the same high technical demands off are required as for the fatty acid • Pump-around condensers distillation. Distillation of oleochemicals • Steam generation (condenser requires attention to the heat recovery) Glycerol following key features:

Fatty Alcohol Distillation Glycerol (C3H8O3), 1,2,3-propan- • High vacuum Fatty alcohols are aliphatic alco- etriol, commonly known as gly- • Low pressure drop hols with carbon chain lengths cerin, is the simplest triol. It is • Low bottom temperature obtained as a byproduct during • Minimum holdup between C6 and C22: the conversion of fats and oils to • Short residence time CH3(CH2)n CH2OH (n = 4 - 20) fatty acids and fatty acid methyl esters. Depending on a customer’s

1212 Oleochemicals - Step into a growing Market with Sulzer Chemtech

Edible Fat and Oil Deodorization Through the use of structured packing, free fatty acids present in vegetable oils must be removed Scrubber with extreme care. The columns Fatty acid operate at a very low vacuum so that it is of immense importance Flash box that the pressure drop in the stripping column is also low. In Stripping comparison with a conventional Column apparatus, steam consumption falls by 70%. Steam

Edible oil for further Fatty Acid Esterification by Edible oil treating free fatty free fatty acid 1-5 % wt acid <0.05 % wt Reactive Distillation Reactive distillation technology Free fatty acid removal for edible and oil treating advantages: • Shift of the chemical equilibrium and increase of reaction conversion by simultaneous separation of products Membrane or Decanter • Suppression of side reactions • Utilization of heat of reaction for Waste water Waste water Fatty acid mass transfer

Different separation possibilites, Reactive distillation applied to fatty depending on the alcohol acid esterification: • Continuous process with Alcohol smooth operating conditions resulting in constant product quality • Short residence time at moderate temperatures avoids Fatty acid ester product degradation • No separation, neutralization or Fatty acid esterification plant with Katapak and MellapakPlus recycling of catalyst necessary • Direct recycle of surplus alcohol Removal • 45% lower energy consumption Filtration Oil free acids compared to conventional batch process Solid Fatty acids

Neutrali- Decant- Fatty acid Biodiesel Reaction methyl ester Biodiesel zation ation drying To be powered by a renewable fuel is not a dream any longer. The Methanol Methanol water biodiesel process overview shows the field of Sulzer Chemtech activi- Catalyst Methanol Glycerol Methanol ties in the green boxes. drying distillation Waste water

Glycerol Biodiesel process

1313 Purified Terephtalic Acid / Acetic Acid

Purified terephtalic acid (PTA) is Dehydration mainly used to create polyester tower fibers (75%) and polyethylene Vent gas teraphtalate (PET) and it is manu- factured through the catalytic liquid Water phase oxidation of p-xylene in acetic acid in the presence of air. Vent scrubber Surge vessel This exothermic process reacts to produce water, which can be removed by a solvent recovery Acetic acid system. The main component of Catalyst this solvent recovery system is the p-Xylene dehydration tower which separates Air acetic acid and water. Recycle

Sulzer Chemtech has been equip- Reactor Terephthalic acid Acetic acid ping new columns and revamping existing units for many years. We are able to handle commonly used materials for this application, in addition to specialized materials such as titanium or zirconium.

0602 2514 0602 2515 Welding device for special materials Round valve trays RV-I

New Column Design Revamp Design

Energy optimized Trays: Packing: - Capacity 135% - ID 100% - ID 75% and 85% - dp=200 mbar - Height 100% - Height 95% - Top purity 3 0.1% wt - Vessel (m ) 100% - Vessel (m3) 62% acetic acid - dp=500 mbar - dp=140 mbar Capacity optimized - Top purity - Top purity 0.3% wt 0.3% wt - Capacity 175% acetic acid acetic acid - dp=250 mbar

- Top purity 0.3% wt acetic acid

14 Flavors, Fragrances and Vitamins - Advanced Distillation Technology at its Best

Flavors, fragrances and vitamins to distill highly sensitive products vary from highly complex mixtures such as flavors, fragrances and to single chemicals. Most of vitamins. Now more than 300 in- these products are temperature dustrial columns are in operation sensitive with close boiling points. for the production of: Thus, a high number of stages in • Citral • Menthol conjunction with a low pressure • Citronellol • Pinene drop is needed to achieve suc- • Eugenol • Tocopherol cessful outcomes. Sulzer gauze • Limonen • And many packing types BX and CY have been others used for approximately 40 years

Continous distillation plant for high purity isomers: 5 Beds BX or CY 100 theoretical stages up to 12 Beds BX or CY 240 theoretical stages

Discontinous multipurpose distillation plant for producing different cuts with specified properties with BX or CY and falling film evaporator

Mellacarbon™ Combines all the advantages of a gauze packing with the corrosion resistance of pure carbon Sulzer Chemtech Gauze Packing Type BX and CY Advantages: • Low pressure drop per theoretical stage • Low liquid holdup per theoretical stage • Low packing height per theoretical stage 0682 2017 • Low intermediate fractions 0697 2522 due to a very low holdup

15 Tall Oil - Sulzer Chemtech Experience and Knowledge - a Winning Combination

Tall oil is an oil from pine, spruce and birch trees, resulting in a byproduct of the pulp and paper manufacturing process. Sulzer Chemtech was the first company to introduce the dry vacuum distillation process with the help of structured packing with the lowest pressure drop.

Key Features of Sulzer Your Benefits with Sulzer Chemtech Technology: Chemtech: • Decades of industrial • Competitive product quality experience and dozens of in- (high acid numbers, excellent house pilot tests color values, high softening • Low pressure drop (bottom point) temperature < 250-270 °C) • Higher yield results from less • Small holdup and high- degradation separation performance • Lower energy consumption • No stripping steam required Higher capacity through • Over 60 industrial column revamping with MellapakPlus references

Head Head

liquid liquid Head CFA PFA Head

liquid DPTO

vapor VRA vapor PFA vapor VRA CTO

BRA

Pitch DTO Pitch Pitch

Depitching Rosin Fatty Acid Super Rosin Column Column Column Column

CTO Crude Tall Oil VRA Vapor Rosin Acid DTO Distilled Tall Oil DPTO Depitched Tall Oil BRA Bottom Rosin Acid PFA Pure Fatty Acid Head Light Ends CFA Crude Fatty Acid Pitch Heavy Ends

16 Air Separation Units

The separation of air components sor, which may be reduced if (Oxygen, Nitrogen, Argon) using the pressure drop through the cryogenic distillation as a process distillation process is kept to a route is characterized by high minimum. A reduction of energy energy requirements reflected in requirements is only possible if the duty of the main air compres- structured packing is utilized.

N2 pure, gaseous 1 High-pressure column N impure, gaseous 2 N2 liquid 2 Low-pressure column O2 gaseous O2 liquid 3 Crude argon column Cooling water Ar 4 Pure argon column impure 5 Direct cooler 5 8 6 Heat exchanger Air

7 Main heat exchanger 10 4 2 3 8 Argon condenser 6 Water 7 9 Evaporator / condenser Ar pure 10 Air compressor 9

Key Features of Structured Packing • Low pressure drop • Energy saving on air compressor • Argon recovery by distillation to Vibration test, 1 ppm O to simulate 2 transportation Higher argon yield and low liquid of assembled hold up columns / cold boxes • Better column flexibility, quicker response time • Larger operating range Horizontal installation of liquid distributor Important Criteria with in the workshop Mellapak / MellapakPlus and of column Internals manufacturer

• Low height, high quality 0602 2516 internals for air separation • Packing and internals for field

and workshop installation 0602 2517 • Horizontal transportation design validation on vibration table and overseas transport • High accuracy of liquid distributors (tested on test rig) Liquid distributor test to confirm • Degreasing to oxygen clean- the correct operation range of each liness 0600 2566-1 distributor

17 Hydrogen Peroxide / Peracetic Acid

For all of your hydrogen peroxide H2O2 - Safety First! needs, Sulzer Chemtech provides The maxim of the chemical industry you with: deserves even more attention when dealing with highly active • Consulting substances such as hydrogen per- • Feasibility studies oxide. Sulzer Chemtech’s unique • Safety concepts approach to address the safety re- • Process design quirements of hydrogen peroxide • Basic engineering has gained wide acceptance around • Key components the world. The confidence our cus- • Redesign and revamps of tomers have in us has made Sulzer existing setups Chemtech the market leader in hydrogen peroxide with more than By adding a feed evaporator, our 40 distillation plants in operation customers are able to produce worldwide. hydrogen peroxide of different purities simultaneously. Our plants The transformation from H O to are designed to produce the entire 2 2 peracetic acid is supported by range of hydrogen peroxide purities Sulzer Chemtech with materials of commercial significance, which testing, computer simulations of allows our customers to perfectly reactive distillation processes and position themselves to market op- joint venture research projects. portunities.

Cooling water

Steam Vacuum Steam ejector Demineralised system water Feed evaporator

Feed Destillation column

Steam

Distillate Cooling Condensate water <0.1% H 2O2

Technical grade product Chemical grade product

Hydrogen peroxide distillation with feed evaporation

1818 Cooling M water Cooling Cooling water water

Steam

Product Feed Distillate Product Feed Distillate Product Feed Distillate

Conventional distillation scheme Steam ejector setup, energy saving: Mechanical vapor recompression, energy 25 to 30% saving: 80 to 85%

Steam ejection and mechanical vapor recompression are energy saving technologies that pay off rapidly and, moreover, are approved and subsidized by go- Condensor vernments in many countries. These technologies are recognized as state-of-the-art in hydrogen peroxide purification and can be applied to a wide variety of other distillation applications.

Packing The “All In One” unit incorporates reboiler, demister, distillation section and a head condenser in a single shell saving investment cost, installation time and plant space. The concept is also applicable to conventional, steam ejector and vapor recompression modes of Demister operation which will pay off in less than one year depending on the cost of local utilities.

Reboiler

All in one distillation unit 0695 2502-2

1919 Pharmaceutical Solvents

More and more, the pharmaceutical Distillation Vapor Permeation Distillation industry relies on Sulzer Chem- tech’s vast experience in thermal separation techniques to meet Impurities their stringent demands for solvent purity.

If it is to: Feed • Debottleneck solvent recovery by switching from batch to continuous processing • Combine various technologies such as distillation, permeation, absorption and crystallization • Avoid of the buildup of impurities Pure ethanol and/or additives during the Water recovery process • Bypass the introduction of additives such as entrainers or anti-foaming agents Ethanol absolution without entrainers. The azeotrope is broken by means of a vapor • Design plants which react fast to permeation membrane avoiding any concern and effort that come along with the changes in operating conditions introduction of entrainers or other additives. • Create processes which adapt themselves to alterations in feedstocks • Assist with IQ, OQ, PQ and other GMP or FDA requirements

Sulzer Chemtech delivers: • Concepts • Feasibility studies (pre- engineering) • Lab- and pilot-scale tests • Process design • Basic engineering • IQ, OQ, PQ assistance • Key equipment such as columns, column internals, heat exchangers... • Modular units (skids)

Distillation and vapor permeation unit 0603 4401

20 Acetates

Reversible chemical reactions Features of Reactive Distillation catalyst, e.g. sulfuric acid). Hete- such as esterifications are ideal rogeneous catalysis (solid catalyst) The reactive distillation technology systems to be treated by reactive is preferred due to the advantage has several advantages, including: a distillation. The unique features of of avoiding catalyst separation shift of the chemical equilibrium and the Katapak® product line include and recycling, which leads to an increae of reaction conversion efficient catalyst contacting, high- the loss of a product or catalyst. by simultaneous separation of separation efficiency and high Furthermore, the position and the products; suppression of side capacity. height of the reaction zone in the reactions and utilization of heat reactive distillation column can of reaction for mass transfer. Ethyl- and Butyl Acetate be pinpointed, which reduces the Compared to conventional de- Synthesis potential of unwanted byproduct signs, these synergistic effects Methyl Acetate Hydrolysis formation. Since there is no free may result in significant economic acid in the column when applying Sulzer Chemtech offers technology benefits, such as: (a) lower capital Katapak-SP, corrosion rates can be license and engineering along with investment, (b) lower energy costs reduced significantly and less cor components for the esterification and (c) higher product yields. rosion resistant materials of con- of ethanol and butanol with acetic struction can be applied, resulting acid to produce ethyl and butyl Catalytic reactions in distillation in lower investment costs. acetate and the hydrolysis of methyl columns are often carried out acetate to produce methanol and homogeneously (using a liquid acetic acid.

Sulzer Chemtech Acetate MeAc Lights MeOH H2O Processes Features H2O • High conversion • High reaction rate • Fewer distillation columns compared to conventional process • No recycle streams • Low energy consumption Pre-reaktor • Heterogeneous catalyst lower corrosion rate • Efficient catalyst utilization by applying Katapak-SP

• Precise reaction zones MeOH, HAc, H2O HAc, H2O HAc • Competitively priced Reactive distillation MeOH separation HAc concentration

Hydrolysis of methyl acetate process

0603 2501-4 Katapak-SP

21 Divided Wall Column

• Divided wall columns from Sulzer Chemtech reduce energy and investment costs • Two columns are combined into A one shell • Three on spec products can be produced with one column • The dividing wall creates a pre- AB fractionator on the feed side, which reduces the chance of pollution of the on spec middle product with the feed on the product side ABC B Sulzer Chemtech offers: • Innovative systems for structured packing and separation trays • Hydraulic designs for the BC complete column • Design and manufacturing for optimal column internals • Mechanical engineering for columns • Process design, control and integration C

0699 2543-1

Sulzer Chemtech has produced pilot and industrial divided wall columns with gauze packing, Mellapak, MellapakPlus and trays with diameters ranging from 43 to 4500 mm

22 Take Benefit from our Knowhow for most of your Problems

Project management Detail engineering of key equipment Purchasing of key equipment Expediting Columns Quality assurance Columns internals Heat exchangers Vessels Modules Basic engineering Process Process flow diagrams Piping and instrument diagrams Control Specification of equipment Startup assistance Layout Training operator Preliminary operating instruction

Additional services and tools Laboratory CFD analysis Mobile plant GC analysis Pilot test Column scanning Absorption test Sulpak for packing design Distillation test Sultray for tray design • Batch • Continuous • Total reflux Column for pressure absorption Distributor test Hydraulic test Site services Project planning Supervision Installation of internals at site Process design or in workshops Tower inspection and repair Distillation simulation Maintenance contracts Spading and despading Code welding Nozzles - design and supply Study Vessel site construction Feasibility study Column dressing Simulation study Third-party inspections Bottleneck analysis NTD co-ordination Energy saving Revamps Turnarounds Column demolition Project management Data analysis from operation Subcontractor coordination Validation Spare parts supply for trays Trouble shooting and other internals Maldistribution analysis

0693 2504-2

23 www.sulzer.com Please check for your local contact

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with The activity program comprises: headquarters in Winterthur, Switzerland, is active in the field of process • Process components such as fractionation trays, structured and engineering and employs some 4000 persons worldwide. random packings, liquid and gas distributors, gas-liquid separators, and internals for separation columns Sulzer Chemtech is represented in all important industrial countries and • Engineering services for separation and reaction technology such as sets standards in the field of mass transfer and static mixing with its conceptual process design, feasibilities studies, plant optimizations advanced and economical solutions. including process validation in the test center • Recovery of virtually any solvents used by the pharmaceutical and chemical industry, or difficult separations requiring the combination of special technologies, such as thin film/short-path evaporation, distillation under high vacuum, liquid-liquid extraction, membrane technology or crystallization. • Complete separation process plants, in particular modular plants (skids) • Advanced polymerization technology for the production of PLA and EPS • Tower field services performing tray and packing installation, tower maintenance, welding, and plant turnaround projects • Mixing and reaction technology with static mixers • Cartridge-based metering, mixing and dispensing systems, and disposable mixers for reactive multi-component material

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Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee of performance. Sulzer Chemtech waives any liability and 22.57.06.40 - X.13 - 10 indemnity for effects resulting from its application.

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